Documentos de Académico
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Documentos de Cultura
October 2010
International Livestock Research Institute (ILRI)
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Citation: Kivaisi, A., Assefa B., Hashim S., Mshandete A. 2010. Sustainable utilization of agro-industrial
wastes through integration of bio-energy and mushroom production. Nairobi, Kenya, ILRI.
Principal investigator:
Co-Principal investigators:
Dr Berhanu Assefa
Chemical Engineering Department
Institute of Technology
Addis Ababa University
P. O. Box 385, Addis Ababa, Ethiopia
E-mail: hmberhanu@yahoo.com
Dr Suhaila Omar Hashim
Department of Biological sciences
Pwani University College
P.O. Box P. O. BOX 195 - 80108, Kilifi, Kenya
E-mail:sohashim@yahoo.com
Dr Anthony Manoni Mshandete
Department of Molecular Biology and Biotechnology
College of Natural and Applied Sciences (CoNAS)
University of Dar es Salaam
P. O. Box 35179, Dar es Salaam, Tanzania
E-mail: mshandete@amu.udsm.ac.tz
Amount Requested:
USD 1.2 M
Duration:
2011-2013
October 2010
2. Executive Summary
Sustainable use of renewable natural resources through value addition using biological life processes is an ideal
transition in a petroleum based economy to bioresource economy, and in addressing climate change. The purpose
of this project is to demonstrate innovative technologies with a potential to utilize agro-industrial wastes currently
seen as low value materials as bioresource to produce value added products at the same time reducing
environmental pollution burden. The project entitled: Sustainable utilization of agro-industrial wastes through
integration of bio-energy and mushroom production proposes to integrate mushroom cultivation and bioenergy
production from coffee processing and sisal wastes for more value addition. The project will establish technoeconomic feasibility of the integrated technologies and disseminate to stakeholders. The direct potential benefits
anticipated in this project include biogas for electricity production, high energy coffee waste briquettes, edible
mushrooms, biofertilizer and public good. The project has a potential to benefit agro processing industries that will
diversify their products through utilization of wastes to produce bioproducts with high economic value thus giving
them a competitive advantage. Delivery of the project is feasible because it will be executed by a consortium made
up of multidisciplinary development partners from Ethiopia, Kenya, Tanzania, Federal Republic of Germany and
Denmark who will complement each other to deliver the expected outputs. The consortium is collabollating with
private sector partners as a platform for future product commercialization. The project is anticipated to last 3 years
and estimated to cost approx. USD 1.5 million.
3. Background and rationale for the proposed project
Biorefining of waste biomass involving the integrated production of chemicals, materials and
bioenergy is a potential alternative for adding significant economic value to the waste as a bioresource. In the
21st century and beyond, bio-resource based economy is envisaged globally as a strategy towards achieving
social, economic and environmental sustainability. Agriculture will be core to the bio-resource based
economy, providing source of raw materials, which are sustainable, plentiful and inexpensive for utilization
in bioprocesses for the production of bio-products. In the Eastern Africas (EA) economy, agriculture is the
mainstay and currently accounts for about 80% of the rural incomes, and coffee and sisal are among the
important cash crops. EA is currently producing about 600,000 tons of coffee beans and about 100,000 tons of
sisal fibre annually. Crop production and processing activities are generating huge quantities of organic waste.
Coffee processing done by wet and dry methods discard away 99% of the biomass generated by the
coffee plants at different stages from harvesting to consumption. This includes cherry wastes, coffee
parchment husks, sliver skin, coffee spent grounds, coffee leaves, and wastewater. Wet processing uses up to
15 m3 of water to produce one ton of clean beans [1] and for every ton of beans produced, about one ton of
husks are generated. It is estimated that coffee processing is generating about 9 million m3 of wastewater, and
600,000 tons of husks annually in the EA region.
Production of sisal fibre from the sisal plant (Agave sisalana) is also a high waste industry currently
using only about 2% of the sisal plant as fibre and the rest being various wastes, including decortications
wastes (wastewater, sisal leaf decortications, sisal short fibres and sisal dusts) and post harvest waste (sisal
stems or sisal boles). The traditional wet sisal leaf decortications process generates about 100 m3 and 25 tons
of wastewater and solid wastes, respectively, per ton of sisal fibres produced. In Tanzania and Kenya, about
20 million m3 of sisal decortications wastewater and 5 million tons of solid sisal decortications wastes are
generated annually [2]. Annual generation of post harvest sisal (stems) boles in both Kenya and Tanzania is
significant and estimated at 4-8 million tons (Katani Ltd, Tanzania, personal Communication).
Agro-industrial wastes generated in EA are mostly underutilized, untreated and thus in most cases
disposed off by burning, dumping or by unplanned landfilling. These practices are a wastage of bioresources
apart from contributing to emission of green house gases (GHG) leading to climate change. At the same time,
utilization of fossil fuels which is also contributing to GHG emissions has become a global concern thus
necessitating the development of alternative cleaner, renewable bioenergy resources. Organic wastes despite
being a menace to the environment, represent a potential bioresource for production of value added products
such as food in the form of mushrooms, feed, bioenergy, biofertilizers and other biobased products [3].
Coffee waste contains high amounts of organic substrates including carbohydrates proteins, pectins,
fibres and fat for bioconversion into value added bioproducts [4]. However, large-scale utilization and
management of coffee wastes around the world still remains a challenge due to caffeine, free phenols and
tannins (polyphenols) which are known to be very toxic to many life processes [5]. Previous studies have
confirmed that toxic materials can be minimized by hot water pretreatment, microbial biodegradation and
aerobic fermentation [6], [7]). To that effect, production of bioproducts such as silage, biogas, worms, animal
feed, ethanol, vinegar, single-cell protein, enzymes, biopesticides, and probiotics have only been established
at small scale thus demonstration of the technology at pilot scale is yet to be achieved. [8], [9]).
Production of oyster mushrooms using coffee husks for mushroom cultivation has been attempted in
southern America [7]. However, utilization of the other coffee wastes for oyster mushroom cultivation is still
in its infancy and not well documented [9]). One of the strategies to utilize other coffee wastes could be
composting of fresh coffee wastes before growing oyster mushrooms. This will not only reduce the toxic
nature, but also help in obtaining high mushroom yields on bulky cheaper coffee waste substrates, thus
making the venture technically realistic and feasible at large scale.
Apart from growing oyster mushrooms to utilize coffee wastes holistically, another innovative
approach is biogas production [8]. The biogas produced could be used for roasting of coffee processing solid
wastes and the waste heat from the roasting unit could be used for pre-drying of the wastes. The roasted coffee
waste would produce briquettes with 70 % less processing cost and 80 % more energy density than the ones
made from raw biomass [10]. However, the feasibility of this concept is yet to be investigated and
demonstrated at pilot scale in EA and elsewhere.
The sisal industry in EA is facing a number of challenges mainly caused by its failure to adopt new
technologies to utilize other parts of the sisal plant apart from hard fibres. A holistic approach to utilize sisal
decortications wastes and post harvest wastes presents a feasible future option for the survival of the sisal
industry [11]. To that effect, efforts have recently been made to diversify bioproducts from sisal wastes.
Mshandete and Cuff [12] reported oyster mushrooms cultivation on solid sisal decortications wastes only at
laboratory scale. However, oyster mushroom production from sisal post harvest wastes has never been
investigated. Furthermore laboratory investigations under the just ended BIO-EARN programme showed that
anaerobic digestion of solid sisal decortications wastes to biogas is technically feasible and could be
improved by various methods [13], [14]). However, production of biogas from post harvest sisal wastes is yet
to be established and demonstrated at pilot scale.
Currently in Tanzania and Kenya, solid sisal decortications wastes are used as feedstock for large
scale biogas production using stirred tank bioreactors (STBR), and conversion of the biogas to electricity.
However, biogas production is limited by the lignocellulosic nature, and high carbon:nitrogen ratio of solid
sisal wastes. Traditionally, hydrolysis of lignocellulosic materials for increased biogas production is achieved
by pre-treatments. The C:N ratio can be manipulated conventionally by blending materials low in carbon
content with those that are high in nitrogen content and vice versa. An innovative way of increasing nitrogen
content of lignocelluloses and at the same time improving on hydrolysis of their fibre components is by fungi
pretreatment, particularly white-rot prior to anaerobic digestion [15]). However, the potential of mixed sisal
decortications wastes and post harvest sisal wastes as substrates for oyster mushroom cultivation and
subsequent utilization of the spent substrates for biogas production is yet to be investigated.
Biogas manure (BgM) is a byproduct obtained from biogas plants after anaerobic digestion of organic
matter. Anaerobic digestion reduces carbon: nitrogen ratio by removing some of the carbon thus increasing
the fertilizing value. BgM is rich in organic matter, supplies essential nutrients, trace elements and other active
substances. It is rich in humic acid that enhances water holding capacity, soil aeration, accelerates root growth
and inhibits growth of weed seeds. The nitrogen released from organic matter during anaerobic digestion,
becomes ammonium which is water soluble and thus readily available for plant uptake. Evaluation of fertilizer
value of BgM resulting from anaerobic digestion of coffee and sisal wastes with integrated oyster mushroom
cultivation has never been done. The proposed project therefore, intends to apply an innovative approach for
the utilization of agro-industrial based organic waste for bioenergy production with integration of mushroom
cultivation, thus adding more value to local bioresources in a sustainable manner, while at the same time
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minimising GHG emissions. Thus, this project fits within the BIO-INNOVATE priority areas of themes 1&2
with respect to climate change adaptability, food productivity and security, value addition to local
bioresources in a sustainable manner and enhancing bioenergy recovery.
References
1. Hue N. V., Bittenbender H. C., and Ortiz-Escobar M. E., (2004). Managing coffee processing water in
Hawaii, Department of Tropical Plant and Soil Sciences, College of Tropical Agriculture and Human
Resources, University of Hawaii, Manoa, Honolulu, HI 96822, USA.
2. Muthangya, M., Mshandete, A.M., Kivaisi, A. K. (2009). J. Agricultural and Biological
Science. 4(4): 66-73.
3. Okonko, I.O., Adeola,O.T., Aloysius,F.E., Damilola, A.O and Adewale, O.A (2009). 8 (4): 263-286.
4. Gathuo, B., Rantala, P. and Maatta, R., (1991). Water Sci Technol, 17(1).
5. 5.Fan L., Soccol A.T., Pandey A.and Soccol , C.R. (2003). Micologia Applicada International 15
(1):15-21.
6. Gaime-Perraud, I., S. Roussos and Martnez. Carrera, D (1993), Micol. Neotrop. Appl., 6: 95-103.
7. Martnez-Carrera, D., A. Aguilar, W. Martnez, M. Bonilla, P. Morales and M. Sobal, (2000). In:
Sera, T., C. Soccol, A. Pandey & S. Roussos (Eds.). Kluwer Academic Publishers.
8. Neves, L., Oliveira,R. and Alves, M.M. (2006). 26 :176181.
9. Murthy P.S. and Manonmani H.K. (2008). Research Jornal of Environmental Science. 2(2):145-150.
10. Bergman, P.C.A and Kiel, J.H.A (2005). Torrefaction for biomass upgrading, Proceeding of 14th
European Biomass Conference & Exhibition, Paris, France.
11. Bisanda, E.T.N and Enock J. (2003). Discovery and Innovation. 15 (1/2): 17-27.
12. Mshandete, A.M and Cuff, J. (2008).. African J. Biotech. 7(24): 4551-4562.
13. Mshandete, A.M. (2005). Ph.D Thesis University of Dar es Salaam, Tanzania.
14. Muthangya M. (2008). M.Sc. Dissertation. University of Nairobi Kenya.
15. Mehta, V., Gupta, J.K. and Kaushal, S.C. (1990). World J. microbial and Biotech. 6:366-370
16. Muthangya, M., Mshandete, A.M., Kivaisi, A. K. (2009). Int. J. Mol. Sci. 10: 4805-4815.
plant producing biogas from sisal decortication waste in Tanzania is obtaining lower biogas yields than
anticipated. This has been attributed to the fibrous nature and poor nutrient ratios of the feedstock. To improve
on the nutrient rations of the waste, the industrial biogas plant for electricity generation recently installed at
Kilifi, Kenya is co-digesting sisal waste with cow manure. The demand for technology to maximize biogas
yields from sisal waste is hence evident. Worldwide it is well established that utilization of coffee wastes in
production of bioproducts is impended by the toxic nature of the wastes. Reduction of toxic nature of the
coffee wastes by growing mushrooms is an innovative approach towards alleviating the problem at the same
time producing a valuable product. Utilization of biogas generated for improving the energy content of coffee
solid wastes for briquettes is yet an attractive innovation. Additionally, BgM has a big potential in organic
crop production which is currently a popular practice generating more revenue from the produce. Within the
Eastern African region, production of edible mushrooms is at a small scale which is hardly satisfying
the fast growing demand for fresh mushrooms locally and by the booming tourist industry. In Kenya,
the current production is estimated at 500 tons per annum and the imports stand at 150 tons per annum. In
Ethiopia, the current demand for fresh mushrooms by hotels and airlines is estimated at about 460 tons and
being catered mostly through imports because the production is much lower. In Tanzania, production stands at
30 tons while the imports stand at about 150 tons. The local market for fresh mushrooms in Eastern Africa is
guaranteed and needs to be satisfied. On the other hand, the global mushroom demand is more than 50 billion
USD annually and is increasing every year by about 20%, hence there is also room for export markets.
Additionally, there is also a growing demand for mushroom-based food supplements as health-
enhancing additions by the local and external markets. Therefore the demand for large scale
production is apparent with a huge impact potential.
The proposed project has a potential to impact on socio-economic development in the participating
countries. First of all, energy from biomass is a sustainable and an environmentally sound means of producing
modern energy. Currently, agro-processing industries depend mainly on thermal/hydro electricity which has
been unrealiable and expensive. Utilization of the wastes that these industries generate for energy production
in the form of heat and power will provide them with a more sustainable, realiable and cost-effective source of
energy. Additionally, energy will be produced locally, thus stimulating local self employment.
Mushroom cultivation is a labour intensive activity and therefore has a potential to employment
opportunities, particularly for villagers within the vicinity of agro-processing factories in order to improve
their livelihood. Mushroom cultivation on a large scale will thus improve on their availability at affordable
cost, and hence provide the people with an additional nutrient rich vegetable which can be of direct benefit to
the human health. Mushroom cultivation is a profitable agri-business and mushrooms can be sold in local
markets or exported to earn foreign revenue that will definitely contribute to sustainable economic
development.
6. Regional and international collaboration
The execution of the proposed project will involve participation of partners in public and private sectors
within the Eastern African region including, Kenya, Tanzania and Ethiopia and international partners from
Germany and Denmark. A regional and international approach is more effective than a national one because it
will broaden the field for the availability of technical know-how, providing a platform for the convergence
and complementing competences and experiences of partners to foster strong linkages to address common
regional developmental challenges such as environmental pollution emanating from agro-processing, climate
change mitigation, and sustainable energy sources in an efficient manner. Additionally, in the wake of the East
African common market, the chances for evaluation, incubation and eventual outlet for developed products is
greater than in a national setting. Besides, the project intends to develop integrated technologies to utilize
agro-industrial waste to generate energy and mushrooms that has a potential to benefit the entire region
through adoption. A regional approach is a more rational way of utilizing funds because it will avoid
duplication of efforts.
7. Project goal and purpose
The development goal of this project is that by 2013, the Eastern African region has in place, pilot scale plants
demonstrating the utilization of agro-industrial wastes by applying an innovative biorefinery approach of
integrating production of edible mushrooms and biogas, and its conversion to electricity thus adding more
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value to the bio-resource. Specifically, the project seeks to establish the feasibility of applying this concept in
the utilization of sisal and coffee wastes to produce oyster mushrooms, and utilize the spent mushroom waste
mixed with selected agro-industrial wastes as a feedstock for improved biogas production. Furthermore, the
project aims at demonstrating the use of biogas for firing an infrared roaster for production of coffee waste
briquettes. The purpose is to get this innovative technology adopted by respective agro-industries for cleaner
production and hence climate change mitigation.
8. Objectives
In order to achieve the stated developmental goal, the following specific objectives must be achieved:
1. To establish technologies for integration of mushroom cultivation with biogas production from coffee and
sisal processing, and sisal post-harvest waste.
2. To evaluate the suitability of coffee solid waste for the production of high energy briquettes utilizing a
biogas fired infrared roaster.
3. To evaluate techno-economic feasibility of the developed technologies.
4. To assess the fertilizer value of the biogas manure.
5. To disseminate the results of the established technologies.
9. Outputs
The project will deliver the following major outputs:
a. Protocols for optimal formulations of substrates and parameters for mushroom cultivation using
coffee and sisal wastes.
b. Laboratory protocols for biogas production from mushroom spent substrate mixtures in two stage and
stirred tank bioreactors.
c. Commercial scale mushroom growing facilities (1000kg/month capacity) utilizing 2000 tons of wet
substrates.
d. Ten (10) cubic meter digesters with a potential to produce a minimum of 5 cubic meters of biogas per
day installed on site at collaborating sisal factories. Assuming a methane content of the gas to be
produced is 60%, the gas to be produced is equivalent to about 9 kWh of electricity and 13.5 kWh of
thermo energy. In the case of coffee waste, the pilot plant size is estimated to produce about 4 m3
biogas/day under normal circumstance. The intended biogas generation volume is estimated from 8
hours gas consumption for firing infrared roaster assuming its consumption rate is equal to house hold
biogas stove consumption, i.e. approximately 300 l biogas/hr.
e. Skilled employees in mushroom cultivation and biogas production at collaborating factories
f. Information on optimal logistics for the mushroom-bioenergy plants and markets for the products.
g. Data on performance of the scaled-up mushroom farm and biogas plants.
h. Information on composition of the upgraded biogas and its suitability for firing an infrared roaster
i. Infrared roaster and briquette making machine fabricated
j. Coffee waste briquettes and data on their energy density.
k. Information on performance of the power generator utilizing biogas
l. Data on fertilizer value of biogas manures.
m. Data on techno-economic feasibility of the integrated technologies
10. Outcomes
The proposed project intends to impact directly and indirectly on the environment and on the economies of the
beneficiaries (starting with the partner factories) and the region at large. Within short and medium terms, the
following outcomes are envisaged: 1) By 2013, a significant decrease in waste disposed off in the vicinity of
the collaborating coffee and sisal-processing factories will have been realized 2) An increase in the number of
employees at collaborating factories due to mushroom cultivation 3) An increase in availability of mushrooms
and their consumption by communities in vicinities of the collaborating factories 4) The project partners that
include Coffee Plantations Development Enterprise in Ethiopia, Kilifi Plantations Ltd in Kenya and
Mohamed Enterprises in Tanzania, will be engaged in running and monitoring the demonstrated systems at
their premises beyond the project period and Memoranda of agreements signed between the partners by the
end of the project. 5) Increased knowledge and skills in mushroom and biogas production among factory
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workers 6) Through proper information dissemination, it is expected that the project outputs will increase
interest in potential stake holders and engage them in verification of the developed technologies and 7) The
project will prompt investments in large-scale spawn (mushroom seed) production industries.
11. Methodology and description of project activities
11.1 Project Design
The project will be implemented under three major components that include 1) coffee processing waste 2)
sisal decortication waste and 3) sisal post-harvest waste in two phases. In Phase 1, the technology will be
established and optimized followed by up-scaling for demonstration and dissemination in Phase 2. The
following specific activities will be carried out:
Phase 1
1. Holding of project inception workshop.
2. Procurement of equipment.
3. Determination of abundance and characteristics of coffee waste streams in Ethiopia, and sisal wastes
at collaborating factories in Kenya and Tanzania.
4. Evaluation of suitability of various coffee waste streams and optimization for oyster mushroom
cultivation.
5. Optimization of substrate formulations using sisal decortication wastes (SDW) and sisal post-harvest
wastes (SPHW) for oyster mushroom cultivation.
6. Investigations on biogas yield potentials of coffee waste spent substrates (CWSS) singly and in
combination with coffee processing wastes (CPW) and other organic wastes in batch bioreactors.
7. Investigations on biogas yield potentials of sisal decortication waste spent substrate (SDWSS) singly
and in combination with sisal processing wastes (SPW) and other organic wastes in batch anaerobic
bioreactors.
8. Investigations on biogas yield potentials of SPHW spent substrate singly and in combination SPW
and other organic wastes in batch anaerobic bioreactors.
9. Examination of performance of a two-stage anaerobic digester for biogas production from selected
blends of CWSS with CPW, other organic wastes and optimization.
10. Optimization of biogas production from selected blends of SDWSS and SPHSS with SPW and other
organic wastes in a laboratory scale stirred tank bioreactor (STBR).
11. Design and construction of demonstration mushroom growing facilities (1000 kg/month capacity) on
site at collaborating factories.
12. Design and construction of a 103 m. demonstration biogas plants.
Phase 2
1. Training of selected factory employees in mushroom cultivation and biogas technology.
2. Commercial scale mushroom cultivation on site at collaborating factories.
3. Start-up, operation and monitoring of scaled-up biogas digesters utilizing the optimal spent substrate
mixtures
4. Coupling of biogas digester to the upgrading unit and electricity generator and monitor
5. Designing and constructing a biogas-fired infrared roaster and briquette making machine
6. Production of briquettes from roasted coffee waste and evaluation of energy density
7. Determination of fertilizer value of resultant biogas manures
8. Determination of optimum logistics for mushroom farm and bioenergy plants, identification of
markets and distribution of the products
9. Carrying out of techno-economic analyses of the established technologies
10. Holding of a dissemination workshop
11. Analysis of results and final reporting
11.2 Methodology
Abundance and characteristics of waste: Field surveys will be conducted at collaborating factories
in Tanzania and Kenya to quantify sisal decortications waste and sisal post harvest waste (boles) while in
Ethiopia, national generation of coffee waste will be established. All waste streams will characterized by
standard methods and will require ovens, furnaces, COD analyses, dissolved oxygen meter, pH probes, etc.
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Oyster mushroom cultivation: Selected strains of oyster mushrooms will be procured from reputable
mushroom culture banks and will be sub-cultured and cryo-preserved. Sub-cultured mushroom strains will
also be used for spawn making. Spawn will be produced using spawn making facilities which include
autoclaves, laminar flow hoods, incubators etc. A cold storage facility shall be used for temporary storage of
the produced spawn prior to propagating on the substrates. In order to determine optimal substrate
formulations that will shorten the crop cycle and increase mushroom yield, different substrate blends and
conditions for oyster mushroom cultivation will be investigated at laboratory scale.
Laboratory scale experiments: Anaerobic batch bioreactors will be constructed using 1L Erlenmeyer
flasks and accessories to investigate biogas yield potentials from spent mushroom substrates and different
blends of spent mushroom substrates with other waste streams. Biogas quantity and content will be monitored
using innovative analytical methods that have been developed in the laboratory. Two-stage anaerobic digester
(for coffee-based waste) and intermittently stirred tank bioreactor (for sisal-based waste) using optimum
substrate blends for biogas production will be tested and operational conditions optimized.
Up-scaling: Mushroom production will be scaled up to 1000kg/month using best coffee and sisal
based substrate formulations in an innovative, low technology farm to be constructed along with a steam
chamber for bulk pasteurization of substrates. A facility for composting coffee waste substrates will also be
constructed. The optimum blends of spent mushroom substrates with other waste streams will be used in
scaling up of biogas production. A two stage (10 cu.m) anaerobic digester will be evaluated for generating
biogas that will be used as feed for a gas-fired infrared dryer/roaster for production of briquettes from solid
coffee waste. A 10 cu.m STBR will be evaluated for production of biogas from optimum sisal waste based
blends. The demonstration plants will be installed in all the three countries on site at development partners
premises. The locations of the plants will be as follows: 1) In Ethiopia, at one of the Coffee Plantations
Development Enterprise factory 2) In Kenya, at Kilifi Plantations utilizing sisal decortications wastes 3) In
Tanzania, at Alawi sisal estate, at one of the factories owned by Mohamed Enterprises Tanzania Ltd utilizing
sisal postharvest wastes (sisal stems/bole).
Coffee waste briquettes production: To produce high energy briquettes from solid coffee waste, an
innovative approach will be employed. This will involve designing and constructing a biogas-fired infrared
roaster for roasting solid coffee waste. Roasted coffee wastes obtained will then be used for making
briquettes using a low technology briquette making machine that does not use conventional binders at
different temperatures and raw materials. The heating value of the briquettes will be determined by using a
bomb calorimeter.
Fertilizer value of biogas manure (BgM): BgM emanating from the biogas plants after anaerobic
digestion of spent mushroom substrate and sisal and coffee-based wastes will be determined by comparing
with other common organic manures and chemical fertilizers in terms of nutrient composition and in growth
of vegetables in green houses or enclosed vegetable farms. Microbial populations in BgM-treated and nonBgM treated soils will be evaluated using standard methods.
Training workshops: In order to demonstrate and transfer the integrated technologies of mushroom and
biogas production from coffee and sisal based wastes to delivery partners, tailor-made training courses for
factory personnel will be conducted on site using the up-scaled mushroom and biogas production facilities in
place.
Biogas upgrading: Biogas will be upgraded using bio-scrubbers to remove hydrogen sulphide, carbon
dioxide and water vapour prior to its utilization for electricity production and firing the infrared roaster.
Logistics and markets: Optimum logistics for mushroom farms and bioenergy plants, and distribution of
their products to the markets will be established. All products supply chain will be studied for the market
centers and respective capacities identified. A mathematical model will be developed to the computation of
the entire process chains and scenarios. Demand for the products and potential market centers, their distance
from the production site will be studied.
Techno-economic analysis: All inputs for project products will be considered in the analyses and
standard feasibility study tools will be used. Both conventional and software methods will be employed.
12. Pathway to impact, applicability of the results in practice and potential impact
A team of biotechnologists, applied microbiologists, environmental and process engineers will carry out
research work to optimize and validate the proposed concepts in the laboratory. The validated technologies
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will be demonstrated by up-scaling on site at partner factories in Ethiopia, Kenya and Tanzania. Here the
technologies will undergo testing, incubation and further improvement in collaboration with the industrial
partners. Techno-economic evaluation will be carried out to establish feasibility of these technologies for
commercialization.
It is expected that the feasible demonstrated technologies will first be adopted by our industrial partners
and later on will be replicated elsewhere in the region. Hence in the long term, the project is anticipated to
impact on the industrial project partners, and other sisal and coffee processing industries, large scale farmers,
and municipalities who will adopt the demonstrated technologies. First, the utilization of the wastes and
residues will significantly reduce environmental pollution and at the same time add value to the waste which
will by then, be regarded as a resource. Secondly the project will provide economic benefits with respect to
savings through use of own generated bio-energy which is sustainable and in line with Millennium
Development Goal (MDG) No. 7 which calls for ensuring environmental sustainability. The partner industries
could benefit from the global carbon credits scheme. Secondly, apart from providing economic benefits and
an alternative protein rich food supplement to the people, commercial scale production of edible mushrooms
will motivate investments in other economic ventures for example mushroom seed production companies, and
packages production companies in the region and most likely result in foreign markets. This will contribute to
economic development in the region.
13. Quality and organization of the consortium
The project team is multidisciplinary, competent, and of a regional character. It is composed of two chemical
and process engineers with experience in biological waste treatment technologies and biogas utilization; two
environmental biotechnologists with a long time research experience in biogas production from agroindustrial wastes and mushroom science; a mycologist with experience in large scale mushroom cultivation;
and a seasoned biochemist with expertise in industrial biotechnology. The team will collaborate with two
international partners including 1) an environmental science and process engineer with expertise in biogas
plant design and extensive experience with two-stage biogas digesters and 2) An environmental
biotechnologist with long term experience with large scale biogas systems utilizing agro-industrial waste.
These individual capabilities complement each other to form a synergy required to execute the stated project
objectives successfully. The partner institutions include the University of Dar es Salaam (UDSM) in Tanzania,
which is the lead institution; Addis Ababa University (AAU) in Ethiopia; and Pwani University College
(PUC) in Kenya. The international collaborators include Brandenburg University of Technology (BTU) and
Danish Technical University in Denmark. For product delivery, the team has three industrial partners
including Coffee Plantations Development Enterprise in Ethiopia, Kilifi Plantations in Kenya, and Mohamed
Enterprises Ltd Sisal Plantations in Tanzania. The roles and responsibilities of development and delivery
partners are shown in Table 1.
Table 1. Roles and responsibilities of project partners
Partner institution
University of Dar es
salaam, Tanzania:
1. Department of
Molecular Biology and
Biotechnology,
2.Department of Chemical
and Process Engineering,
Development partners
Scientist
Roles
Prof. Amelia Kivaisi
PI-Project coordination; Dissemination
Dr Anthony Manoni
CO-PI; Technology development: Integration of
Mshandete
production of mushroom with biogas production utilizing
sisal boles; Dissemination; Providing backstopping
expertise at PUC
Dr. Oscar Kibazohi
Dr N. Mwaluko
Dr. Suhaila Omar
Hashim
10
Dr Berhanu Assefa
Brandenberg University of
Technology, Germany
Danish Technical
University
Name of Industry
Mohamed Enterprises
Tanzania Ltd (Sisal
plantations)
Coffee Plantations
Development Enterprise,
Ethiopia
Kilifi Platantions Kenya
Dr Dawit Abate
Dissemination of results
Project coordination (CO-PI);
Technology development: Two stage biogas digester using
coffee waste;
High density coffee waste briquette production;
Dissemination
Technology development: mushroom cultivation utilizing
coffee waste; Dissemination
(MA) by Co-Principal Investigators (CO-PI) and at project level by the Principal Investigator (PI). The main
focus will be on completing each aspect of the project on-schedule within the budget. Regular meetings to
evaluate the progress in details in terms of expected outputs as per activities carried out, to identify problems
and make any decisions about the changes in the strategy. At project level, annual meetings of all
developmental partners will be held. Monitoring will also be through six-monthly reports where
achievements will be evaluated against the planned activities where a monitoring Ghant chart will be used to
track progress. Furthermore, the project progress will be monitored by performing a self evaluation exercise
annually at MA and project levels.
Dissemination and communications plans: All the achievements will be disseminated through
publications in peer reviewed scientific journals and presented at national, region and international
conferences. Project results will also be published in trade journals to reach a wider audience where our
innovative approach to utilize agro-industrial wastes will be advertised in the Eastern African region. The
information will not only be disseminated to the scientific and technical recipients, but also to the public and
policy makers through workshops. Specifically, training workshops on biogas/mushroom technologies for
collaborating factory workers, and (2) a dissemination workshop at the end of project period will be
conducted. Leaflets and brochures with project results will be printed out and distributed among different
research organizations. Two simple handbooks one in mushroom cultivation and the other on biogas digester
monitoring will be produced.
Intelectual property and other policy issues: All Intellectual Property (IP) issues will be guided by
IP policies of all partner institutions as well as corresponding host countries. However, for common interest,
all partner institutions will operate within an alliance agreement framework to be formulated and agreed upon
after inception of the project. It will include: 1) Material transfer agreement to cater for materials such as
biological agents to be transferred from one institution to another. Purpose, use and sharing of outputs from
use of the materials among the institutions will be stipulated in the agreement 2) Record keeping of research
information, confidentiality and non disclosure agreement among partner institutions and with private sector
partners. This agreement intends to inform all researchers on how to maintain research logbooks (dates and
entries) and that any material, notes or discoveries belonging to the project should be kept confidential in
order to avoid unauthorized use of research output resulting in financial loss to researchers and partner
institutions 3) Patenting in case of new inventions will be stipulated to cover how and where to apply for a
patent, and which institution will be an applicant and how to share proceeds from commercialization of patent
4) The framework will clearly specify collaboration agreement with private partners. Agreement will include
ownership of research equipment during and after project life cycle, responsibility and duties of private
partner and participating institutions, material transfer agreement, loyalties beyond project life cycle if the
partners wished to continue with and/or upscale production based on project findings, and non discloser to
third party and transfer of technology to a third party agreement. Agreements with private partners will be
signed at the commencement of the project.
16. Milestones and time frame
Milestones towards achieving project objectives are shown in the Table 2 below.
Table 2. Milestones towards project goal
Milestones
Completion of waste auditing and optimization of oyster mushroom cultivation on
coffee and sisal wastes
Completion of investigations on biogas yield potentials of mushroom spent substrates
and blends
Lab scale optimization experiments with coffee-based waste in a two stage anaerobic
bioreactor completed
Lab scale optimization experiments with sisal-based wastes in stirred tank bioreactors
completed
12
Period (months
after start of
project)
9
8
23
12
12
12
23
23
22
22
23
23
Data for biogas manure fertilizer value obtained and information on markets for
project products
Optimum logistics for mushroom farm and bio-energy plants and distribution of
products determination completed
Techno-economic analyses completed
33
36
33
33
13
Project duration
Activity description
1
Year 1 (Quarters)
3
14
Year 2 (Quarters)
3
Year 3 (Quarters)
Optimization of biogas
production from selected blends
of sisal decortication and post
harvest spent substrates in STBR
Design and construction of
demonstration mushroom
growing facilities
Design and construction of upscaled demonstration biogas
plants
Training workshops for selected
factory employees on mushroom
cultivation and biogas
technology
Commercial scale mushroom
cultivation on site
Start-up, operation and
monitoring of scaled-up biogas
digesters
Biogas upgrading and
monitoring
Design and construct a biogasfired infrared roaster and
briquette making machine
Roasted coffee waste briquettes
production and evaluation of
energy density
Coupling of up-graded biogas to
power generator and monitor
Determination of optimum
logistics for mushroom farm and
bio-energy plant and distribution
of their products
Identification of markets for the
resultant products
Evaluation of fertilizer value of
15
biogas manure
Techno-economic analyses
Final dissemination workshop
Analysis of results and final
reporting
Annual meetings between
project partners
19.
Year 1
Year 2
AAU
Equipment
Lab./consumables
Travel
Fieldwork costs
Contractual labor*
PUC
79700
11300
26338
-
UDSM
Year 3
AAU
PUC
UDSM
Total
AAU
PUC
UDSM
70040
60850
46450
27800
64182
19500
4500
4700
5340
6410
4271
5750
5310
3000
4100
16165
24440
27251
37816
27665
12115
9825
13400
2400
2550
373022
50181
195015
4950
24700
75400
84250
36350
45700
38000
13550
1000
1000
Consultancy
1000
9500
9500
8500
5000
2080
2000
3500
2000
2000
2000
Workshops
21840
1400
1500
6440
11880
Training costs
4100
12650
14150
1145
3000
Overhead
6944
1000
1000
7000
2874
Coordination costs*
6600
3120
7320
10050
8120
32000
7800
3120
17000
Unforeseen
3750
1500
1500
3500
1500
1500
2000
2000
2000
19250
159332
170425
211540
146990
139857
187747
60344
56385
67380
1,200,000
43.45
46.48
45.33
40.08
38.14
40.23
16.46
15.38
14.44
Total
% of total allocation
16
319950
28500
18580
43060
35045
18818
95130
*Contractual labor includes casual labor, research assistants, design and construction works; coordination includes management cost, travel of PI and CO-PIs, meetings
17
Table 4. Budget per main activity per EA partner institution for the period 2011-2013
MAJOR ACTIVITIY
TOTAL (USD)
PARTICIPATING INSTITUTIONS
AAU*
PUC*
UDSM*
8,000
1,550
14,585
24,135
65,200
23,190
17,250
105,640
8,245
2,115
15,355
25,715
1. Inception workshop
69,623
4. Technology development and optimization23,933
for coffee waste,
26,990 sisal wastes
18,700and sisal postharvest
wastes
98,520
5. Design and construction of mushroom farms
21,160
40,260
37,100
64,700
76,190
154,390
13,787
10,120
25,860
49,767
5,000
5,000
5,508
1,500
1,500
8,508
159,333
170,425
211,540
541,298
YEAR 2 (2012)
1. Design and construction of biogas utilization
36100
system(infrared
roaster-briquetting
0
system)* 36,100
156,188
1. Commercial mushroom cultivation for demonstration
17535
59171
79482
14270
7700
29,285
6300
6450
12,750
39796
38090
136,286
21875
21,875
16800
8620
19750
45,170
4. Dissemination of results
4940
10200
12900
28,040
5. Contingency
3,500
1500
1,500
6,500
187,747
474,594
21125
37,840.0
11210
6000
7600
24,810.0
3. Identification of markets
3500
3000
3500
10,000.0
9445 -
9,445.0
5. Techno-economic analysis
3000
4000
13000
20,000.0
7273.5
3620
18000
28,893.5
7. Dissemination
4800
16640
23280
44,720.0
8. Contingency
4400
2000
2000
8,400.0
67,380
184,109
466,667
1,200,000
Subtotal
146,990
139,857
YEAR 3 (2013)
1. Biogas upgrading, monitoring and utilization
16715
2. Determination fertilizer value
6. Project Management
Subtotal
60,344
56,385
366,666
366,667
18
Logframe
Title of Consortium Project: Sustainable utilization of agro-industrial wastes through integration of bio-energy and mushroom production
Goal of the Project: The development goal of this project is that by 2013, the Eastern African region has in place, pilot scale plants demonstrating the
utilization of agro-industrial wastes by applying an innovative bio-refinery approach of integrating production of edible mushrooms and
biogas.
Outputs
Outcome
Performance
Indicator of Outcome
Data Source
Collection Method
Objective # 1: To establish technologies for integration of mushroom cultivation with biogas production from coffee processing
and sisal wastes.
1.1 By 2013, a significant 1.1 The quantity of
Protocols for optimal
Progress
Surveys/visits
decrease in waste
waste used for
formulations of substrates
Interviews
report
disposed off in the
mushroom
and conditions for oyster
vicinity
of
the
cultivation, biogas
mushroom cultivation by
Factory
collaborating coffee
and briquette
January 2012
reports
and sisal-processing
production
Optimal conditions for
factories
1.2 The number of
digesting the spent
Site visits
1.2
An
increase
in
the
employees for the
substrate mixtures in twonumber of employees
mushroom farms
stage bioreactor and in
at
collaborating
and bio-energy
stirred tank bioreactor
factories
due
to
plants
Dec. 2012
mushroom cultivation
1000 kg/ month -scale
1.3 An
increase
in 1.3 Quantity of
mushroom growing
availability
of
mushrooms sold to
facilities and 10,000L
mushroom
to
communities
biogas digesters installed
communities
in
on site at collaborating
vicinities
of
the
factories by Sep. 2012
1.4 MOUs signed
factories
between the
1.4
The
project
delivery
Data on performance of
partners by 2013
partners
engaged
in
scaled-up biogas digesters
running
By Dec. 2013
and monitoring the
19
Assumptions - Assessment of
Progress/Achievements
Political situation is
conducive in the region
Alliance of agreement for
the consortium signed
MOUs between
development and delivery
partners signed and parties
complying
Project funds per activity
delivered timely
demonstrated systems
at their premises
beyond
Objective # 2 : To evaluate the suitability of coffee solid waste for production of high energy briquettes utilizing a biogas fired
infrared roaster
At least one additional
Infrared roaster and 2.1 The technology
Surveys/visits
Progress reports
briquette making
Interviews
prompted interest in other factory shown interest
machine
coffee processing
and a collaboration
Coffee waste
factories
MOU signed by 2013
briquettes and data
on their energy
density.
Objective # 3: To evaluate techno-economic feasibility of the improved technologies
Information on optimal
logistics for the
mushroom bio-energy
plants ans available
markets for the resultant
products
Techno-economic
feasibility of the
integrated technologies
Progress
reports
Surveys/visits
Interviews
Competence to develop
improved process gained
More effective linkages with
factory formed
Project funds per activity
delivered timely
Political situation is
conducive in the region
Alliance of agreement for
the consortium signed
MOUs between
development and delivery
partners signed and parties
complying
Demonstration plants in
place and operating
Project funds per activity
delivered timely
4.1 Decrease in
utilization of commercial
fertilizer on sisal and
20
Progress
reports
Surveys/visits
Interviews
MOUs between
development and delivery
partners signed and parties
manure.
Site visits
21
Progress
reports
Factory
reports
Paper
reprints
Copies of
brochures
and books
Visits
Interviews
complying
Experimental plots made
available by partner
plantations
Organic food producers to
utilize the manure present
ANNEX
Qualifications
1978: BSc (General), University of Dar es Salaam, Tanzania
1984: MSc in Microbiology, Stockholm University, Sweden
1990: PhD (Applied Microbiology), University of Dar es Salaam, Tanzania
Scientific experience
Auditing of waste materials including mapping. Biogas production from waste organic materials.
Anaerobic digestion of lignocellulosic materials using rumen microorganisms and optimization of the
processes including application of biological pre-treatment. Mushroom production. Lignolytic
enzymes in basidiomycetes. Composting of municipal solid waste. Supervised over 25 postgraduate
research students and published over 50 scientific publications in referred journals.
Managerial skills
Coordinator of a number of research projects, under the sponsorship of NUFFIC-The Netherlands for
12 years and SIDA/SAREC-Sweden for more than 10 years. Chief Editor of the Tanzania Journal of .
Science for 3 years.
Recent publications since 2008
1. Anthony Manoni Mshandete, Lovisa Bjrnsson, Amelia Kajumulo Kivaisi, Mugassa,
Steven Thomas Rubindamayugi, Bo Mattiasson.(2008). Performance of biofilm carriers in
anaerobic digestion of sisal leaf waste leachate. Electronic Journal of Biotechnology
[online]. 15 January 2008, vol. 11, no. 1 [cited date]. Available from Internet:
http://www.ejbiotechnology.info/content/vol11/issue1/full/7/index.html. ISSN 0717-3458.
2. Anthony Manoni Mshandete, Lovisa Bjrnsson, Amelia Kajumulo Kivaisi, Mugassa,
Steven Thomas Rubindamayugi, Bo Mattiasson.(2008). Two-stage anaerobic digestion of
aerobic pre-treated sisal leaf decortications residues: hydrolases activities and biogas
production profile. African Journal of Biochemistry Research2: 211-218
3. Anthony Manoni Mshandete, Lovisa Bjrnsson, Amelia Kajumulo Kivaisi, Mugassa,
Steven Thomas Rubindamayugi, Bo Mattiasson.(2008). Effect of aerobic pre-treatment on
production of hydrolases and volatile fatty acids during anaerobic digestion of solid sisal
lead decortications residues. African Journal of Biochemistry Research. 2(5): 111-119.
4. Muthangya, M, Mshandete, A.M. Kivaisi, A.K. (2009). Enhancement of anaerobic
digestion of sisal leaf decortication residues by biological pre-treatment. ARPN Journal of
Agricutural and Biological Science. Vol 4(4), 66-73.
5. Muthangya, M, Mshandete, A.M. Kivaisi, A.K. (2009). Two-stage fungi pre-treatment for
improved biogas production from sisal leaf decortication residues. Int. J. Mol. Sci. 10,
4805-4815.
22
24
Scientific experience
Industrial material and energy auditing; designing pollutant removal of system from industrial effluents;
process effluent treatment and technology selection; designing, building and operating waste treatment
unit and investigating the performance of treatment unit; investigation of removal of fluoride from
ground water membrane technology and adsorption using local materials; industrial wastewater
treatment using membrane technology; - investigating of lab single and two stage biogas generations
from vegetable solid wastes; cities solid waste generation, characterization and management strategies.
Solid waste stream analysis for energy potential and
Managerial Skills
Assistant dean of the Faculty of Technology, AAU, from 2006 to 2009; Principal investigator of project
on two stage biogas generations from vegetable solid wastes funded by Ethiopian Ministry of Science &
Technology from 2008 - 2009; Principal investigator of project on Textile Factory wastewater treatment
using membrane technology, which was funded by Ministry of Water Resources from 2008 to 2009; CoPrincipal investigator of IGNIS project on recovery of resources from Municipal Solid Waste in a
sustainable way in emerging mega- cities and converting into biogas, compost, etc. It is financed by
German Government from 2008 - 2013. Supervised over 15 M.Sc student thesis dissertations and 5
projects since 2003, currently supervising 3 M.Sc students, and one project on producing simple hand tool
to cover dry waste organic solid into dense briquette fuel
Publications
Berhanu A., Investigation of the performance RO membrane for fluoride removal, Zede Journal
of Ethiopian Engineers and Architecture, 21, 1 - 12.
25